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LoadRunner™ SeriesOnBoard Weighing System for Dump Trucks

OnBoardScales.com Installation & Service

Manual

162356 Rev A

Contents

1.0 Introduction..................................................................................................................................... 11.1 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.2 Considerations Before Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

1.2.1 Welding Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

2.0 Load Pin and Transducer Specification ......................................................................................... 32.1 Onboard Dump Truck Kit Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32.2 Load Pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42.3 Pressure Transducer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

3.0 Roll Off Load Pin Installation .......................................................................................................... 53.1 Installing the Load Pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53.2 Installing the Inclinometer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83.3 Power Cable Connection to Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93.4 Hydraulic Pressure Transducer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93.5 Routing Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103.6 Install the Indicator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

3.6.1 Electrical Wiring and Data Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123.7 Final Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

4.0 Configuration and Calibration ...................................................................................................... 134.1 User and Setup Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134.2 Initial Setup of the OB-350 Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

4.2.1 Initial Password Entry and Clock Setup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154.2.2 Configuration of Input Channels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

4.3 Configuration of Count By . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164.4 Configuration of Zero Function. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164.5 Configuration of Inclinometer Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164.6 Configuration of Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174.7 Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

4.7.1 Calculating the SPAN (Net Weight) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174.7.2 Enter Tare Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184.7.3 Set Zero Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184.7.4 Full Span (Net Load) Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

5.0 Service and Troubleshooting........................................................................................................ 205.1 System Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205.2 Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205.3 Sensor Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

5.3.1 Load Pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205.3.2 Visual Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

5.4 Cables and Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215.4.1 Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215.4.2 Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Hardware Warranty Statement ................................................................................................................. 22

© Rice Lake Weighing Systems. All rights reserved. Printed in the United States of America. Specifications subject to change without notice.

Rice Lake Weighing Systems is an ISO 9001 registered company.Version 1.0, May 7, 2014

Contents i

ii LoadRunner™ Series Installation & Service Manual

1.0 IntroductionThis manual is intended for use by technicians responsible for installing and servicing LoadRunner Series Onboard Weighing Systems.

This manual contains instructions for installing various types of Onboard Weighing Systems (non Legal-for-Trade systems). For straight trucks, this manual includes rigid under-body mounting instructions in four and six point configurations, as well as under-body load pin installation instructions for tipping bodies and hoist chassis. Tipping body installations can be either Lift-to-Weigh or Live-Weigh system types.

Authorized distributors and their employees can view or download this manual from the Rice Lake Weighing Systems distributor site at www.ricelake.com.

Important

CAUTION

WARNING

DANGER

1.1 SafetySafety Symbol Definitions:

Indicates an imminently hazardous situation that, if not avoided, will result in death or serious injury.

Indicates a potentially hazardous situation that, if not avoided, could result in serious injury or death, and includes hazards that are exposed when guards are removed.

Indicates a potentially hazardous situation that, if not avoided, may result in minor or moderate injury.

Indicates information about procedures that, if not observed, could result in damage to equipment or corruption to and loss of data.

General Safety

WARNING

Do not operate or work on this equipment unless you have read and understand the instructions and warnings in this manual. Failure to follow the instructions or heed the warnings could result in injury or death. Contact any Rice Lake Weighing Systems dealer for replacement manuals. Proper care is your responsibility.

Failure to heed may result in serious injury or death.DO NOT allow minors (children) or inexperienced persons to operate this unit.DO NOT operate without all shields and guards in place.DO NOT jump on the scale.DO NOT use for purposes other than weight taking.DO NOT place fingers into slots or possible pinch points.DO NOT use any load bearing component that is worn beyond 5% of the original dimension.DO NOT use this product if any of the components are cracked.DO NOT exceed the rated load limit of the unit.DO NOT make alterations or modifications to the unit.DO NOT remove or obscure warning labels.Keep hands, feet and loose clothing away from moving parts.

Introduction 1

WARNING

1.2 Considerations Before InstallationFailure to observe these recommendations and instructions could result in a hazardous operating condition.

This manual is intended to provide information for the mounting of Onboard Weighing Systems sensors in a variety of applications. In applying the installation procedures, which follow, some fundamental precautions and recommendations must be observed by the installer:

• Rice Lake Weighing Systems’ Onboard Scales are designed for applications covering a broad range ofvehicle types. Things to take into consideration are:

- Significant variations in mountings- Variations in load sensor models- Specifications- System configurations

• Installation procedures are similar for both new vehicle mountings and retro-fit mountings. When doing aretro-fit mounting, ensure that all vehicle structures are free from cracks, excessive wear, corrosion,alignment problems, etc. that could affect safety and scale performance.

• Load cells, load cell bearing plates, mounting brackets and load cell hardware should be painted uponinstallation to help protect the installation from corrosion. Industry appropriate, quality enamel paint isrecommended.

- For environments where high concentrations of salts are used on road surfaces, under-body coating isrecommended (3M™ Underseal™ part number 3M-8883 Universal Rubberized Undercoating).

- Load cells, bearing plates, brackets and hardware should be periodically inspected for any evidence ofrust or corrosion. If areas of corrosion are present, they should be cleaned with a wire brush andre-painted or undercoated.

- Load cell connectors must be connected or capped during painting or undercoating.• The instructions outlined herein are designed to ensure that a correct installation will provide maximum

safety, optimum system performance and accuracy, a long operating life, and reasonable installation costs. Itis required that the installer comply with all guidelines and material specifications outlined in this manual,with special emphasis on detail and inspection of work.

• Installation must comply with appropriate regulations of the U.S. Department of Transportation (DOT), stateand local regulations, the recommended standards and practices of the Society of Automotive Engineers(SAE), standards of the American Welding Society (AWS), and the recommendations of the truck, trailer andbody, hoist and/or suspension manufacturer.

1.2.1 Welding SpecificationsWelding, metalworking and assembly should only be performed by qualified personnel experienced in welding on vehicle body structures and sub frames. Only welding equipment of the highest quality should be used in the welding of load cell bearing plates. When welding, use procedures that ensure high quality welds. Over-welding may result in distortion and damage, while under welding may not develop adequate strength.

ImportantRice Lake Weighing Systems recommends removal of load cell after tack welding bearing plates in position so that final welding is performed without load cell being subjected to excessive heat, weld current, or cable damage.

If welding with load cells in position, the installer must ensure that electrical current cannot flow through the load cell. All load cell terminals must be shorted together. Attach the ground strap directly to the vehicle frame member to which the bearing plates will be welded. Never weld directly to a load cell.

WARNING Always disconnect battery terminals before performing any welding.

2 LoadRunner™ Series Installation & Service Manual

2.0 Load Pin and Transducer SpecificationThe Rice Lake Roll Off and Dump Truck kits are typically LIFT-TO-WEIGH KITS. This means that with the hoist in the relaxed state (on the chassis), no weight reading is available. The hoist needs to be elevated to a position showing the correct angle on the in-cab digital display unit, approximately four degrees, for the weight reading degrees to be valid and accurate.

NoteThis manual provides instructions for the installation of straight frame dump trucks and “pup” dump trailers only. For information on full frame or frame-less end dump or side dump trailers, please refer to the Rice Lake Precision Loads manual (PN 115094).

2.1 Onboard Dump Truck Kit Parts

3 415 6

7

22

8

9

10111213

1514

Figure 2-1. Onboard System – Dump Truck Kit Illustration

Table 2-1. Onboard System – Dump Truck Kit Parts List

Item No. Part No. Description Qty

1 119966 Support, 1 x 4 x 5.16 12 119963 Ring, .25 x 2.25 x 3 43 131207 Pin, Load Dump Truck 24 119974 Glass Tubing 25 119973 Load Cell Mount Weldment 26 119969 Weldment, Support Ring 27 153117 Screw, Cap 1/2-20NF x 5” 28 Nut, Top Locking 29 131800 Cable Assembly 6’ 310 131226 Splitter, Cable Y-Splitter 111 131222 Inclinometer, Onboard 1

158196 Bracket, Onboard Inclinometer 112 131228 Cable Assembly 15’ (5M) 113 131200 Transducer, Hydraulic 114 131219 Indicator, OB3502 Channel 115 131221 Cable Assembly Fuse 1

Load Pin and Transducer Specification 3

2.2 Load PinsHinge pivot and lift cylinder load pins built by Rice Lake Weighing Systems are available in two sizes:

• 2 inch diameter (see Figure 2-2) Dump TruckFull length hinge bars are also available as direct replacements for tipping bodies with hinge bars (contact a Rice Lake Weighing Systems dealer or the factory). All load pins are supplied with collars and bolts with locknuts to secure pin position. The installer must ensure that all load pin installations can receive required initial and periodic lubrication.

ElectricalConnector

Double shear load pinmade from heat treated alloy steelnickel plated for corrosion resistancefitted with an M12 commercial vehicle class connector

11.8" (300 mm)

2"(49 mm)

0.79"(20 mm)

5.5"(142 mm)

0.79"(20 mm) 0.5 Ø (14 mm )

Orientation andAnti-rotation

Reaction Force

Reaction Force

2.4"(62 mm)

6.4"(162 mm)

2"(53 mm)

Chamfer0.12" (3 mm) x 45°

Both Ends

0.4"(10 mm)

Ø 2" d10 Ø 50.7050.58

Direction of LoadDirectionof Load

Figure 2-2. 2 Inch Diameter Load Pin (PN 131207)

2.3 Pressure Transducer

1.2" A/F(30 mm) 0.25" (6 mm)0.31"

(8 mm)

2" (50 mm)

1" Ø

(26 mm)

9/16

"-18

SAE 1.2" Ø

(33 mm

)

16' (5 M) if four core cablewith a M12 fully moulded male connector

Material: Stainless SteelSealing: Fully welded to IP68

Figure 2-3. Oil Pressure Transducer (PN 131211)


3.0 Roll Off Load Pin Installation

ImportantAll load pin installations require lubrication facilities. Normally lubrication is provided through the central pivot area. OEM Roll Off pivots typically have existing lubrication fittings included in their pivots. Rice Lake pivots are furnished with drilled and tapped holes for the insertion of a standard lube zerk which must be supplied and installed by the system installer.

Load Pin Kits

Inclinometer

Y Cable

Battery

Transducer

Indicator

Power Cable

Homerun Cable

Figure 3-1. LoadRunner System Layout

3.1 Installing the Load Pins1. Remove the rear fenders from the truck, if required, to gain free and clear access to the pivots.2. Use jacks or a forklift to support the rear of the dump bucket and maintain its position/alignment while the

pivot pins are being replaced.3. Remove the bolt and washer from the collar/support on the pivot.

NoteRemoving pivot pins on some vehicles may be difficult if rust is present or if the hoist chassis pivot and the truckchassis supports are out of alignment. If rust is an issue, use a penetrating lubricant and appropriate tools for tapping the pivot pin out. Use a pry bar as a lever to assist with any misalignment problems to remove the existing pivot pins.

4. Push the pivot pins out of the supports.5. Mark the frame where the pivot supports are located, in an area that will not be affected by grinding the

frame smooth. This will assist in the location of the new supports.6. Remove the supports from the frame of the truck.7. Using a power grinder or a wire brush, clean the area where the supports were located, both sides of the

frame. Grind the frame smooth to ensure a clean weld for the support installation.

Roll Off Load Pin Installation 5

8. Weld supports to frame according to Figure 3-2.

3/8"Typ

0.50"

3/8" Typ3/8"

3/8"

??

Support PlateSupport Plate

Support Collar WeldmentSupport Collar Weldment

Truck Angle

Figure 3-2. Weld Supports to Frame


9. Install each mount assembly and load pin per Figure 3-3.

Never strike the load cell directly, as it may cause damage to the load cell. Use a wood block (or similar material) to cushion the load cell, and tap lightly.

Important

Step 1

Insert neoprene bushing into the support opening.

Step 2

Place a collar over the neoprene bushing and snug against the support.Step 3

Place the mount weldment over the neoprene bushing between the supports.

Step 4

Press the neoprene bushing farther in to the mount weldment to hold it.

Step 5

Place the remaining collar into the space between the mount weldment and the spacer.

Step 6

Press the neoprene bushing the rest of the way in to support the components.

Step 7

Push the load pin through the neoprene bushing, aligning the holes in the load pin and the support.

Step 8

Secure load pin to the support using a bolt and nut.

Left Rear - Connector should be toward the cab

Right Rear - Connector should be away from the cab.

Cab of Truck

Step 9

Using grease, lubricate the neoprene bushing.

Figure 3-3. Install Load Pins Assembly

NoteThe load pins have arrows indicating the downward force, or direction of load applied to register a positive weight value. See Figure 2-2 for load pin specifications and load direction.


3.2 Installing the InclinometerInclinometer should be installed on the hoist as close as possible to the load pins. Grind off any paint or rough areas of the frame.

Inclinometer Bracket

Hoist Frame

Inclinometer

ImportantThe inclinometer should be installed on a flat surface that will not interfere with any moving parts on the frame. It must be installed as level to the frame as possible.

Figure 3-4. Install Inclinometer

NoteRice Lake Weighing Systems recommends one of the following mounting options, dependant on the type of truck frame the unit is being mounted to.

Mounting Bracket Option 11. Align the mounting bracket to the frame and mark the holes.2. Set the bracket aside and drill holes in the frame where marked.3. Align the bracket with the holes and secure with bolts, washer and nuts.

Mounting Bracket Option 21. Align the mounting bracket to the frame and mark the holes.2. Weld mounting studs to the frame where marked.3. Place the bracket on the mounting studs and secure with washers and nuts.

Mounting Bracket Option 31. Align the mounting bracket to be level with the frame.2. Weld around the bracket to secure to frame.

Installing Inclinometer1. Install the inclinometer to the bracket using the hardware included. The cable connection should be at the

bottom.


3.3 Power Cable Connection to Battery

Brown wire to positive

Fuse

Blue wire to negative

Figure 3-5. Power Connection to Battery

1. Wire the fuse (5A) to the brown wire.2. Connect the power cable to the battery.

- Brown wire connects to positive terminal.- Blue wire connects to ground.

3.4 Hydraulic Pressure TransducerThe hydraulic pressure transducer should be installed at the hydraulic control valve.

Tee Fitting

Reducing Fitting

TransducerHydraulic Valve

Figure 3-6. Install Hydraulic Pressure Transducer

1. Remove the hose where the transducer is to be installed.2. Install a tee fitting to connect the hose to the hydraulic valve.3. Insert a reducer if required (9/16” straight thread with O-ring is required to fit the Rice Lake pressure

transducer) to the opening in the tee where the transducer is to be installed.4. Run the cable along the frame to the cable access hole in the cab. Wire-tie the cable to the frame.

Important

Note Allow for slack when fitting and securing hydraulic hose lines as these move during normal operation.

Plan a transducer cabling route that has little or no risk of pinching, stretching or melting the cables.Use split loom on all exposed cable to protect in areas where damage could be an issue.


3.5 Routing WiringBecause each truck is different, cable routing will be specific to the truck the system will be installed on.

ImportantPlan a route that has little or no risk of pinching, stretching or melting the cables.Use split loom on all exposed cable to protect in areas where damage could be an issue.Wire tie any excess cable to the frame.

NoteFor cab-over type truck cabs, all scale system cabling must run around the main pivot point of the cab-over hinge. For conventional cabs, look for cab access grommets in the flooring near the driver seat area.

For ease of connection, label the cables used in installation prior to threading through the hole into the cab.

1. Connect 6’ cables to the load pins.2. Connect the load pin cables to the Y cable.3. Connect 15’ cable and 3’ cable (if necessary) to the Y cable.4. Route the 15’ cable along frame to the indicator through access hole in the cab.5. Wire tie the cable to the frame approximately every 18 inches.6. Follow the same route with the inclinometer cable.7. Route the power cable from the battery to the indicator location.

Load Pins

Inclinometer

Y Cable

Battery

Transducer

Indicator

Power Cable

15’ Cable

6’ Cable

Note Connecting wiring to the indicator is shown in Section 3.6.

Figure 3-7. Wiring Diagram


3.6 Install the Indicator

Panel mount

Roof/under dash mountDash mount

Optional Radio DIN mount

Figure 3-8. Indicator Mounting Options

If the indicator will be installed in the cab, choose an area that is easily visible to the driver. A mounting bracket is provided.

0.71 in(18 mm)

4.00 in(100.5 mm)

2.50 in(62.5 mm)

5.71 in(145 mm)

1.73 in(44 mm)

5.71 in(145 mm)

4.80 in(122 mm)

1.57 in(40 mm)

2.32 in(59 mm)

3.54 in(90 mm)

3.54 in(90 mm)

Ø 0.25 in (6.5 mm)holes for u-brackets

0.157 in (4 mm) self taper0.137 in (3.5 mm) deepPanel mount holes

ImportantWhen running cable to the indicator, use existing access hole if available, if not, a hole will need to be drilled in the cab. Insert a grommet to protect wiring.

Do not allow cable jacket to contact bare metal edges.

Figure 3-9. Indicator Dimensions


3.6.1 Electrical Wiring and Data ConnectionsThe indicator is fitted with one Power and one Input Channel connector as standard. CANbus, Channel 2 and RS-232 are optional. Full connector options are shown below.

1 3

2 4

5 612B1D4FBT

Figure 3-10. Rear Panel Identification and Bulkhead Connectors

1 Input Channel 1, Max +/-39.0625 milli-Volts (Hydraulic Pressure Transducer)

2 Input Channel 2, Max +/-39.0625 milli-Volts (Load Pin Connection)

3 Power Input

4 CANbus digital input & output (Inclinometer Connection)

5RS-232 output for printers and data capture devices (pin 9 = vehicle volts, pin 5 = ground, pin = 2 transmit, pin 3 = receive)

6 Alpha-numeric unique indicator serial number, also appears on power-on

POWER & ALARM, socket is MALE – CON 1 on PCB

Pin 1 BROWN Vehicle voltage Supply 12V (LCV) or 24V (MCV & HGV)

Pin 2 WHITE Output 1 12V or 24V

Pin 3 BLUE Ground Ground 0 Volts (common)

Pin 4 BLACK Output 2 12V or 24V

3.7 Final Installation1. Reinstall the fenders.2. Test the hoist to make sure none of the cables at risk of being pinched, stretched or cut when it is raised and

lowered.3. Test the hoist to make sure the scale reads positively with applied weight. If positive weight is not

displayed, it is possible that the load pins or a load pin are not in the correct position and readingbackwards. Pin position can be changed by rotating 180 degrees.


4.0 Configuration and Calibration

4.1 User and Setup MenuThe menu structure has two levels of security: an open user menu for driver operators and a password setup menu for calibrations and options for making changes to the user menu.

Note

OptionsAlarms

Alarm 1

Alarm 2

Cells

CAN

Diagnostics

Menu

OLED

Info

Display

Split

Input 2

Input 1

Configuration

Span

Zero

Tare

Calibration

ModesRS-232

PRINTERCount

1 lb

10 lb

20 lb

50 lb

100 lb

200 lb

INC

ON

OFF

System

PUK

Pin

Clock

Net

Gross

Net & Gross

ON

OFF

Chan

Load

Z/Func

Keyboard

Inhibit

Keyboard

Printer

Printer CSV Data

Printer G PVWS

None

Format 1-4

Scoreboard

Net 4

Gross 4-5

G PVWS

BA4840

The default password is 0350. Keep this for your records.

Figure 4-1. User and Setup Menu – Electrical Wiring and Data Connections

User and Setup Menu

Parameter Choices Description

Display OLEDInfo

Adjust the brightness of the display; High, Med or Low. Firmware version and serial number display.

Diagnostics CellsCAN

To display mV/V for load cells or transducers on separate channels.To display CANbus diagnostics (not used).

Alarms Alarm 1Alarm 2

Allows configuration of audible alarms.

Table 4-1. User and Setup Menu – Electrical Wiring and Data Connections

Configuration and Calibration 13

The following configuration and calibration instructions require symbols to make selections. When selecting a symbol, press the corresponding key below the symbol. See Figure 4-2.

(OK) Symbols

Keys

Figure 4-2. Symbol Keys

4.2 Initial Setup of the OB-350 IndicatorThe system password allows access modification of the options: Configuration, Calibration and System Setup menus. When in the configuration and setup menus, the function keys will perform the following functions:

MENU

(OK)

DiagnosticsAlarmsOptions

Configuration CalibrationSystem

A B C D

E

Figure 4-3. Setup Mode

A Accept or Enter key - enters data

B Down arrow key - scrolls down within the menu selection

C Up arrow key - scrolls up within the menu selection

DCarriage Return/Circle - Previous screen or back functionWhen in a menu function (password) and OK is not visible, use this key as the enter and accept.

E Selectable MENU options

Options Modes Select weighing mode to be displayed - Net. Gross or Net & Gross. See Section 4.6.Load/Chan Load function gives the option to accumulate the amount of load (weight) delivered or

collected from site.

Channel Function - Split screen function is added to the MENU screen. RS-232 Select or change RS-232 output option. Count Select count by in kg - 1, 2, 5, 10, 20, 50, 100, 200, Z/Func Allows operator access to Zero/Tare function on the display.Inc For use with roll off systems and dump trucks, turn on to calibrate zero degrees of

inclinometer.Configuration Input 1(F)

Input 2 (R)SplitCAN

Air/Oil pressure transducer or load cell setting on truck type.Air/Oil pressure transducer or load cell setting on truck type.Setting varies depending on input 1/input 2 values.Not Used

Calibration TareZeroSpan

Entry of empty vehicle weight for gross weight calculation.No load zero calibration.Entry of load for span calibration.

System PinPUKClock

Enter a password.Not Used.Change system time and date.

User and Setup Menu

Parameter Choices Description

Table 4-1. User and Setup Menu – Electrical Wiring and Data Connections


4.2.1 Initial Password Entry and Clock Setup1. Press the power button to power on the indicator.2. Press the Circle key to enter the menu screen.3. Use or to scroll to System.4. Press (OK).

5. Press to select Pin.

6. Press (OK) to display PIN input screen.

7. Enter Password or Pin code, 0 3 5 0, using the following:

• Press or to number 0-9.

• Press to move cursor left.

8. When PIN is correct, press to enter code.

9. Press (OK) to accept PIN.

10. Press to back up to MENU.

11. To Set PIN, select PIN, press (OK) and repeat 2 - 6.12. Use or to scroll to Clock. 13. Press (OK).

14. Select the edit key to modify time (military) and date (international)• Press or to number 0-9.

• Press to move cursor left.

15. When complete, press three times to exit and return to system setup menu

4.2.2 Configuration of Input Channels1. Scroll to Configuration.2. Press (OK).3. Press (OK) with Input 1 selected.4. Press (OK) again to configure the channel.5. Use or to scroll to Air/Oil Transducer.

6. Press .7. Use or to scroll to Input 2. 8. Press (OK) again to configure the channel.9. Use or to scroll to load cells.

10. Press to return to the system setup menu.


4.3 Configuration of Count ByThe count by value in the division size, in lbs, that the scale will increment by on the display.

1. Use or to scroll to Option. Press (OK).

2. Use or to scroll to Count. Press (OK).

3. Use or to scroll to the Count By value. Press . Selectable count by values are 1, 2, 5, 10, 20, 50, 100 and 200 lbs.

NoteRice Lake Weighing Systems recommends using 20 lb minimum. Choosing a lower weight value may cause your weight to fluctuate on the display and returning to zero weight may be more difficult. Example: If 50lb is selected, the weight values will increase by a factor of 50lbs: 50, 100, 150, etc.

4. Scroll to Z/Func: and press (OK).

4.4 Configuration of Zero FunctionThe Zero function setting allows you to turn on and off the zero key when in normal weighing mode.

Selectable zero function settings are:

• Allow Keypad Zero – Activate container tare (Gross Mode) or Zero (Net Mode) button on main menu tozero load up to 1100 lbs of weight by the operator.

Note When the tare button is pressed in gross mode, the weight will return to the original empty weight tare value.

• Inhibit zero – De-activate operator zero functionality

To set the Zero Function:

1. In MENU, select Options.

2. Press (OK).

3. In OPTIONS menu, select Z/Func.4. Press (OK).

5. Use or to scroll to desired option.

6. Press to confirm setting.7. Zero is be added to the MENU screen.

4.5 Configuration of Inclinometer Calibration On dump truck and roll off applications, the load runner system uses the load pins and hydraulic pressure transducer to determine a weight value. To achieve the best accuracy, calibrate the system at the same incline that weight will be read, with +/- 1-2°.The Inclinometer setup screen shows both the body angle in a numeric value and absolute angle (abs 0.0). For this application, use the level indicators, which light up for every degree the body is raised. The numeric value will indicate a negative value as the body is raised, which is normal. The level indicators to the right will light up, 1° per circle. The inclinometer function allows visual determination of the height of the body to achieve an accurate weight value consistently.

1. Make sure the truck is on a level surface and the body is in the downposition.

2. Scroll to Option, press (OK).

3. Scroll to Inc, press (OK).

4. Use to scroll to ON.

5. Ensure the body is in the down position and the truck is on a levelsurface.

6. Press CAL to zero the inclinometer.


4.6 Configuration of ModesWith the inclinometer option turned on, the inclinometer screen is visible by switching display screens when pressing the menu button.

The display screen will toggle between the following when configured for:

Gross Mode:Toggles between gross only weight display, inclinometer standard display and menu mode

Net Mode:Toggles between net only weight display, inclinometer with net weight display and menu mode

Net and Gross Mode (factory recommended setting):Toggles between net only weight display, gross only weight display, inclinometer with net weight display and menu mode.

To set mode:

1. In MENU, select Options.

2. Press (OK).

3. In OPTIONS menu, select Modes.

4. Press (OK).

5. In MODES menu, press to toggle between NET & GROSS

GROSS

NET

6. Press to confirm setting.

4.7 CalibrationCalibration requires the use of a truck scale in order to calibrate the system. First determine the empty vehicle weight or tare weight of the truck. Once the tare and zero calibration are performed, load the vehicle as close to its legal maximum limit as possible to determine the span or net weight value used for calibration.

4.7.1 Calculating the SPAN (Net Weight)1. To determine actual TARE weight, drive the empty vehicle onto a truck scale and note the total weight.

Truck Scale

Figure 4-4. Vehicle on Truck Scale

2. Load the vehicle as close to its legal maximum as possible.3. Weigh the loaded vehicle, using the same truck scale, and record the GROSS vehicle weight.4. Calculate NET weight using: Gross - Tare = Net.

NotePrior to calibration, with the display in the Inclinometer/Net Weight or Inclinometer mode raise the body clear of the chassis (the factory recommendation is three or four degrees). Record the bubble indication setting for use on span calibration and normal weighing.


4.7.2 Enter Tare Weight

lb

lb

lb

lb

lb

1. Ensure vehicle is empty, then weigh and record TARE (empty vehicle) weight on an accurate truck scale.

2. In MENU screen, select Calibration and press ok.

3. Select Tare.

4. Press ok (defaults to 10000).

5. Press edit.6. Enter vehicle TARE (empty) weight recorded in Section 4.7.1.

7. Press .

8. Press again to return to MENU screen.

Prior to calibration, with the display in the Inclinometer/Net Weight or Inclinometer mode raise the body clear of the chassis (the factory recommendation is three or four degrees). Record the bubble indication setting for use on span calibration and normal weighing.

Note

4.7.3 Set Zero Calibration lb

lb1. Make sure the vehicle is on level ground.

Tippers: raise the body clear of the chassis, approximately three or four degrees.

2. In CAL menu, press to select Zero.

3. Press ok.

4. Press cal.

5. Press ok to Confirm Ch 1 Zero.

6. Press to return to CAL menu.

NoteThe Rice Lake Roll Off and Dump Truck kits are typically LIFT-TO-WEIGH KITS. This means that with the hoist in the relaxed state (on the chassis), no weight reading is available. The hoist needs to be elevated to a position showing the correct angle on the in-cab digital display unit, approximately 4 degrees, for the weight reading degrees to be valid and accurate.


4.7.4 Full Span (Net Load) Calibration

lb

lb

lb

lb

lb

lb

1. Load vehicle to its legal max, record GROSS weight.2. Weigh and record the TARE (empty) vehicle.

3. Subtract the TARE weight from the GROSS weight to give the SPAN (NET) weight.

31900 -12500 =19400 kg SPAN (NET) PAYLOAD

If the vehicle is a tipper, raise the body clear of the chassis.4. In CAL menu, press to Span.

5. Press ok (defaults to 22680 lb).

6. Press edit.

7. Edit the SPAN (NET) weight, as in steps 1 & 2 above.

8. Press when done.

9. Press cal.

10. Press ok to Confirm Ch 1 Span cal.

11. Press twice to return to MENU screen.


5.0 Service and Troubleshooting

5.1 System MaintenanceThis section of the manual is intended to assist the user with techniques for system maintenance and troubleshooting. Maintenance of the onboard scale can be done quickly and needs to be done at regular intervals.

For service issues make sure you have original test numbers to work with, the test numbers help locate a problem source quickly. Scale meters are built with simple but effective internal system diagnostics programs that isolate component performance.

With reference to onboard scale service and repair procedures that involve load pins, trunnions and air transducers, some fundamental precautions and recommendations must be observed by servicing personnel.

WARNINGFailure to observe these recommendations and instructions could result in a hazardous operating condition.

• Servicing personnel must ensure that all vehicle structures are free from cracks, excessive wear, corrosion,alignment problems, etc. that can affect safety and scale performance.

• The instructions outlined herein are designed to ensure that a properly serviced installation will providemaximum safety, optimum system performance and accuracy, for a long operating life. It is thereforeextremely necessary that the installer comply with all guidelines and material specifications outlined in thismanual, with special emphasis on detail and inspection of work.

• Service and repair work must be in compliance with appropriate regulations of the U.S. Department ofTransportation (DOT), state and local regulations, the recommended standards and practices of the Societyof Automotive Engineers (SAE), standards of the American Welding Society (AWS), and therecommendations of the truck, trailer and body, hoist and/or suspension manufacturer.

5.2 CalibrationSystem calibration needs to be performed at the time of original scale installation. Rice Lake Weighing Systems recommends that scale calibration be repeated about one month after original scale installation to adjust for any mechanical influences that “seat” a new scale.

There is no typical interval for scale calibration that can be universally specified. Instead, operators should keep comparison data of onboard scale loads as compared to weights obtained from certified platform scales or pre-measured loads. If this is not possible, six-month re-calibration intervals are recommended. See Section 4.7.

5.3 Sensor Maintenance

5.3.1 Load PinsFor hinge load pins, thorough pin lubrication is critical to proper scale performance. Ensure all load pins used in roll-off and other pin applications are always well-lubricated.

5.3.2 Visual InspectionAt the end of each day, service personnel should perform visual inspections that look for:

• Signs of wear or “polishing”• Signs of weld cracking or failure• Evidence of excessive corrosion• Evidence of potential chassis• Body runner or support structure cracking or bending

When the load pins were originally installed, instructions specified that mounting brackets required clean, flat, rigid and co-planar surfaces for welding. If these surfaces have become cracked, corroded or out of alignment, then corrective action must be taken to ensure proper performance and safety of the onboard scale installation.


5.4 Cables and Connectors5.4.1 CablesInspect for any loosening of cables that might result in exposure to damage. Repair by adding more cable ties to tighten up the cable run.

5.4.2 ConnectionsRice Lake Weighing Systems uses special connectors which do not corrode and can withstand extremely cold conditions. When aluminum connectors are present, especially in environments with high humidity or road salts, the connectors should be periodically cleaned and protected with plumbers tape. If a connector is severely corroded, contact Rice Lake Weighing Systems for replacement information.

Service and Troubleshooting 21

Hardware Warranty StatementRice Lake Weighing Systems (RLWS) warrants that all RLWS brand equipment and systems properly installed by a Distributor or Original Equipment Manufacturer (OEM) will operate per written specifications as confirmed by the Distributor/OEM and accepted by RLWS. All systems and components are warranted against defects in materials and workmanship for two (2) years, unless otherwise stated.

RLWS warrants that the equipment sold hereunder will conform to the current written specifications authorized by RLWS. RLWS warrants the equipment against faulty workmanship and defective materials. If any equipment fails to conform to these warranties, RLWS will, at its option, repair or replace such goods returned within the warranty period subject to the following conditions:

Upon discovery by Buyer of such non-conformity, RLWS will be given prompt written notice with a detailed explanation of the alleged deficiencies.

Individual electronic components returned to RLWS for warranty purposes must be packaged to prevent electrostatic discharge (ESD) damage in shipment. Packaging requirements are listed in a publication, "Protecting Your Components From Static Damage in Shipment," available from RLWS Equipment Return Department.

Examination of such equipment by RLWS confirms that the non-conformity actually exists, and was not caused by accident, misuse, neglect, alteration, improper installation, improper repair, or improper testing. RLWS shall be the sole judge of all alleged non-conformities.

Such equipment has not been modified, altered, or changed by any person other than RLWS or its duly authorized repair agents.

RLWS will have a reasonable time to repair or replace the defective equipment. Buyer is responsible for shipping charges both ways

In no event will RLWS be responsible for travel time or on-location repairs, including assembly or disassembly of equipment. Nor will RLWS be liable for the cost of any repairs made by others.

Installer is completely responsible for the design and fitting of the installation, and any changes which might result in voidance of the warranty of the manufacturer of equipment to which the products are installed.

THESE WARRANTIES EXCLUDE ALL OTHER WARRANTIES, EXPRESSED OR IMPLIED, INCLUDING WITHOUT LIMITATION WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. NEITHER RLWS NOR DISTRIBUTOR WILL, IN ANY EVENT, BE LIABLE FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES.

RLWS AND BUYER AGREE THAT RLWS' SOLE AND EXCLUSIVE LIABILITY HEREUNDER IS LIMITED TO REPAIR OR REPLACEMENT OF SUCH GOODS. IN ACCEPTING THIS WARRANTY, THE BUYER WAIVES ANY AND ALL OTHER CLAIMS TO WARRANTY.

SHOULD THE SELLER BE OTHER THAN RLWS, THE BUYER AGREES TO LOOK ONLY TO THE SELLER FOR WARRANTY CLAIMS.

No terms, conditions, understanding, or agreements purporting to modify the terms of this warranty shall have any legal effect unless made in writing and signed by a corporate officer of RLWS and the Buyer.


Hardware Warranty Statement 23

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